Torque Specifications For the Vulcan 1500 Series
Vulcan Classic & Nomad Torque Specs
These torque specs are as accurate as the Kawasaki maintenance manual they came from. Please use judgement if anything seems way out of line and note the number of left hand threaded fasteners.
|
Threads Dia (mm) |
Torque (ft-lb) |
|---|---|
|
5 |
30 ~ 43 in lb |
|
6 |
52 ~ 69 in lb |
|
8 |
10.0 ~ 13.5 |
|
10 |
19.0 ~ 25.0 |
|
12 |
33 ~ 45 |
|
14 |
54 ~ 72 |
|
16 |
83 ~ 115 |
|
18 |
125 ~ 165 |
|
20 |
165 ~ 240 |
-large">Notes
G: Apply grease to the threads EO: Apply engine oil to the threads and the seating surface L: Apply a non-permanentlockng agent to the threads LH: Left-hand threads MO: Apply molybdenum disulfide oil to the treads and seating surfaces S: Tighten the fasteners following the specified sequence SS: Apply silicone sealant ST: Stake the fasteners to prevent loosening R: Replacement parts
|
Fastener |
Torque |
Notes (above) |
|---|---|---|
| Fuel System | ||
| Fuel Filter Nuts | 87 in lb | |
| Fuel Hose Clamp Screws | 22 in lb | |
| Vacum Sensor Nut | 87 in lb | |
| Atmospheric Pressure Sensor Nut | 87 in lb | |
| High Pressure Fuel Hose Clamp Screws | 13 in lb | |
| Pressure Regulator Screws | 43 in lb | |
| Delivery Joint Screws | 30 in lb | Throttle Body |
| Throttle Cable Holder Screw | 30 in lb | L |
| Throttle Body Flanged Bolts | 43 in lb | |
| Throttle Assy Holder Bolts | 104 in lb | Right Side |
| Inlet Manifold Bolts | 104 in lb | On Cylinder Head |
| Exhaust Header Bolts | 14 ft lb | On Cylinder Head |
| Full Throttle Stopper Screw | _ | L, LH |
| Second Lead Holder Bolts | 87 in lb | Right side |
| Air Cleaner Duct Holder Bolts | 87 in lb | Left side |
| Right & Left Air Cleaner Base Bolts | 104 in lb | |
| Right & Left Air Cleaner Base Screws | 19 in lb | L, Lower Duct |
| Left Air Cleaner Duct Tapping Screws | 19 in lb | |
| Left Air Cleaner Cover Allen Bolt | 12 | |
| Right Air Cleaner Cover Allen Bolt | 12 | |
| Right Air Cleaner Allen Bolts | 95 in lb | Throttle Body |
| Choke Cable Plate Screw | 26 in lb | L, Throttle Body |
| Inlet Air Temperature Sensor Nut | 69 in lb | |
| Water Temperature Sensor | 13 | SS |
| Fuel Pump Bolts | 61 in lb | S, L |
| Return Fuel Check Valve | 14 | |
| Cooling System | ||
| Radiator Hose Clamp Screws | 22 in lb | |
| Coolant Air Bleeder Bolt | 69 in lb | |
| Radiator Fan Switch | 13 | |
| Water Temperature Switch | 65 in lb | SS |
| Water Pump Impeller Bolt | 87 in lb | Lh |
| Water Pump Cover Bolts | 87 in lb | |
| Water Pump Drain Bolt | 87 in lb | |
| Water Pipe Bolts | 87 in lb | |
| Radiator Drain Bolt | 65 in lb | |
| Clutch | ||
| Clutch Lever Pivot Bolt | 8.7 in lb | |
| Clutch Lever Pivot Bolt Locknut | 52 in lb | |
| Clutch Reservoir Cap Screws | 13 in lb | |
| Clutch Slave Cylinder Bleed Valve | 69 in lb | |
| Clutch Slave Cylinder Bolts | - | L |
| Clutch Hose Banjo Bolts | 18 | |
| Clutch Master Cylinder Clamp Bolts | 87 in lb | S |
| Starter Lockout Switch Screws | 10 in lb | |
| Push Rod Guide Bolts | 87 in lb | L |
| Clutch Cover Bolts | 87 in lb | |
| Clutch Cover Damper Bolts (outside) | 87 in lb | L |
| Clutch Cover Damper Bolts (inside) | 87 in lb | EO |
| Clutch Cover Damper Screws | 43 in lb | L |
| Clutch Hub Nut | 108 | EO |
| Engine Top End | ||
| Spark Plugs | 13 | |
| Spark Plug Retainer | 104 in lb | |
| Air Suction Valve Cover Bolts | 65 in lb | |
| Chain Tensioner Mounting Bolts | 87 in lb | S |
| Chain Tensioner Lockbolt | 43 in lb | S |
| Chain Tensioner Cap | 14 | S |
| Timing Inspection Plug | 13 in lb | |
| Rotor Bolt Plug | 13 in lb | |
| Camshaft Sproket Bolts | 11 | L |
| Oil Hose Flange Bolts | 87 in lb | |
| Rocker Shafts | 18 | |
| Rocker Case Nuts 12 mm | 58 | EO, S |
| Rocker Case Nuts 8 mm | 18 | S |
| Rocker Case Bolts 6 mm | 78 in lb | S |
| Cylinder Head Nuts | 18 | S |
| Cylinder Head JAcket Plug | 14 | L |
| Rocker Case Cover Bolts | 78 in lb | S |
| Camshaft Chain Guide Bolts | 87 in lb | L |
| Cylinder Nuts | 18 | S |
| Inlet Manifold Bolts | 104 in lb | |
| Exhaust Pipe Cover Clamp Bolts | 61 in lb | |
| Engine Lubrication System | ||
| Oil Filler Cap | 13 in lb | |
| Oil Screen Plug | 15 | |
| Engine Oil Drain Plug | 15 | |
| Oil Filter (cartridge) | 13 | EO, ft |
| Oil Filter Bolt | 18 | SS |
| Oil Pressure Relief Valve | 11 | L |
| Oil Pressure Switch Terminal Bolt | 13 in lb | |
| Oil Pressure Switch | 11 | SS |
| Oil Pump Cover Screws | 69 in lb | |
| Oil Pump Mounting Bolts | 87 in lb | |
| Oil Hose Banjo Bolts | 87 in lb | |
| Oil Hose Flange Bolt (outside) | 87 in lb | |
| Oil Pipe Holder Bolts (inside) | 78 in lb | L |
| Oil Pipe Clamp Bolts (inside) | 87 in lb | L |
| Right & Left Crankcase Oil Nozzles | 30 in lb | x3 |
| Oil Reserve Tank Bolt | 78 in lb | |
| Crankcase Breather Hose Clamp Screw | 13 in lb | |
| Engine Removal/Installation | ||
| Downtube Bolts | 32 | |
| Engine Mounting Bolts & Nuts | 32 | |
| Engine Mounting Bracket Bolts | 18 | |
| Engine Ground Terminal Bolt | 69 in lb | |
| Wheels & Tires | ||
| Front Axle Clamp Bolt | 25 | S |
| Front Axle Nut | 79.6 | S |
| Rear Axle Nut | 79.6 | |
| Spoke Nipples | 26 ~ 65 in lb | |
| Final Drive | ||
| Oil Pipe Banjo Bolts (Front Gear) | 104 in lb | |
| Oil Nozzle (Front Gear) | 26 in lb | |
| Oil Nozzle (Front Gear) | 13 | |
| Neutral Switch | 11 | |
| Front Gear Case Bolts (6 mm) | 104 in lb | Mar 9 |
| Front Gear Case Bolts (8 mm) | 22 | |
| Speed Sensor Bolt | 87 in lb | L |
| Damper Cam Nut (Front Gear | 166 | MO (threads) |
| Drive Gear Nut (Front Gear) | 195 | MO, ST |
| Driven Gear Assy Mounting Bolts | 18 | |
| Driven Gear Bolt (Front Gear) | 101 | MO, ST |
| Bearing Retainer Bolts (Front Gear) | 78 in lb | L |
| Final Gear Case Drain Plug | 78 in lb | |
| Final Gear Case Mounting Nuts | 25 | |
| Final Gear Case Studs | - | L |
| Final Gear Case Cover Bolts (8 mm) | 17 | |
| Final Gear Case Cover Bolts (10 mm) | 25 | |
| Pinion Gear Nut (Final Gear) | 86.8 | St, MO |
| Pinion Bearing Retainer (Final Gear) | 181 | Lh |
| Retainer Stop Screw | 12 | L |
| Brakes | ||
| Caliper Bleed Valves | 69 in lb | |
| Brake Hose Banjo Bolts | 18 | |
| Brake Lever Pivot Bolt | 8.7 in lb | |
| Brake Lever Pivot Bolt Locknut | 52 in lb | |
| Front Brake Reservoir Cap Screws | 13 in lb | |
| Front Brake Light Switch Screw | 10 in lb | |
| Front Master Cylinder Clamp Bolts | 78 in lb | S |
| Front Caliper Mounting Bolts | 25 | |
| Rear Caliper Mounting Bolts | 25 | |
| Rear Caliper Holder Bolt | 47 | |
| Brake Disc Bolts | 20 | L |
| Rear Master Cylinder Mounting Bolts | 18 | |
| Rear Master Cylinder Push Rod Locknut | 13 | |
| Brake Pedal Clamp Bolt | 18 | |
| Suspension | ||
| Piston Rod Nut | 14 | |
| Front Fork Top Plug | 16 | |
| Upper Front Fork Clamp Bolts | 14 | |
| Lower Front Fork Clamp Bolts | 25 | |
| Lower Front Fork Cover Bolts | 65 in lb | |
| Front Fork Cover Screws | 39 in lb | |
| Front Fork Bottom Allen Bolts | 14 | L |
| Front Axle Clamp Bolt | 25 | S |
| Spacer Bolt | 35 in lb | |
| Rear Shock Absorber Nuts | 25 | |
| Shock Absorber Air Valves | 47 in lb | |
| Swingarm Pivot Shaft | 94 | G |
| Steering | ||
| Steering Stem Head Nut (the chrome one) | 65 | |
| Steering Stem Nut (the serrated one) | 14 ft lbs for 1500's, 43 in lbs for 1600 | |
| Handlebar Clamp Bolts | 25 | S |
| Handlebar Holder Nuts | 25 | |
| Handlebar End Caps | - | Lh, L |
| Handlebar Switch Housing Screws | 30 in lb | |
| Upper Front Fork Clamp Bolts | 14 | |
| Lower Front Fork Clamp Bolts | 25 | |
| Headlight Cover Bolts | 65 in lb | |
| Upper Fork Cover Bolts | 39 in lb | |
| Brake Joint Bolts | 65 in lb | |
| Turn Signal Light Holder Bolts | 65 in lb | |
| Frame | ||
| Front Fender Bolts | 61 in lb | |
| Downtube Bolts | 32 | |
| Front Footboard Bracket Bolts | 25 | |
| Rear Footpeg Bracket Bolts | 14 | |
| Sidestand Nut | 32 | |
| Electrical | ||
| Spark Plugs | 13 | |
| Pickup Coil Screws | 26 in lb | |
| Stator Lead Holder Screw | 87 in lb | L |
| Pickup Coil Lead Holder Bolt | 87 in lb | L |
| Alternator Outer Cover Bolts | 104 in lb | |
| Alternator Cover Joint Bolts | 104 in lb | |
| Alternator Outer Cover Damper Bolts | 87 in lb | EO (tip) |
| Alternator Cover Bolts | 87 in lb | |
| Alternator Inner Cover Bolts | 87 in lb | |
| Alternator Rotor Bolt | 57 | EO |
| Alternator Outer Stator Bolts | 113 in lb | L |
| Alternator Inner Stator Bolts | 113 in lb | L |
| Timing Inspection Plug | 13 in lb | |
| Starter Motor Terminal Locknut | 95 in lb | |
| Starter Motor Terminal Nut | 43 in lb | |
| Starter Motor Assembly Bolts | 43 in lb | |
| Starter Motor Mounting Bolts | 87 in lb | |
| Headlight Body Mounting Screws (inside) | 26 in lb | L |
| Headlight Rim Screws | 8.7 in lb | |
| Handlebar Switch Housing Screws | 30 in lb | |
| Starter Lockout Switch Screw | 10 in lb | |
| Front Brake Light Switch Screw | 10 in lb | |
| Sidestand Switch Bolt | 78 in lb | L |
| Radiator Fan Switch | 13 | |
| Water Temperature Switch | 65 in lb | SS |
| Oil Pressure Switch Terminal Bolt | 13 in lb | |
| Oil Pressure Switch | 11 | SS |
| Neutral Switch | 11 | |
| Turn Signal Light Lens Screws | 8.7 in lb | |
| Turn Signal Light Mounting Nuts | 52 in lb |
Mick